Components for electrical connectors, and metal strip therefore

Abstract

Electrical connector or electrical switching element including a metallic core and a galvanically deposited metal containing coating layer is presented. The metal containing coating layer is deposited by electrolytic composite plating and the coating layer includes a metal matrix and distributed therein particles selected from the group of particles having electrically conductive properties, particles having lubricating properties, particles having wear resistance properties and particles having properties of increasing the temperature durability or combinations of particles from those groups. The electrical connector or electrical switching element has been made from a continuously coated metal strip comprising a metallic core and a galvanically deposited metal containing coating layer. A continuously coated metal strip for manufacturing such electrical connectors is also presented.

1 . Electrical connector or electrical switching element comprising a metallic core and a galvanically deposited metal containing coating layer, the metal containing coating layer being deposited by electrolytic composite plating and the coating layer comprises a metal matrix and distributed therein particles selected from the group consisting of particles having electrically conductive properties, particles having lubricating properties, particles having wear resistance properties and particles having properties of increasing the temperature durability or combinations of particles from those groups, wherein the electrical connector or electrical switching element has been made from a continuously coated metal strip comprising the metallic core and the galvanically deposited metal containing coating layer.  
     
     
         2 . Electrical connector or electrical switching element according to  claim 1 , wherein the electrically conductive particles are selected from the group consisting of carbonaceous materials, and electrically conductive ceramic materials comprising borides, nitrides; sulfides, and electrically conductive oxides.  
     
     
         3 . Electrical connector or electrical switching element according to  claim 1 , wherein the particles having lubricating properties are selected from the group consisting of polymers, carbon containing particles, ceramic particles, and lubricating means containing capsules, and optionally the particles having lubricating properties also having corrosion inhibiting additives.  
     
     
         4 . Electrical connector or electrical switching element according to  claim 1 , wherein the particles having wear resistance properties are selected from the group consisting of ceramic particles, and optionally carbonaceous nanotubes.  
     
     
         5 . Electrical connector or electrical switching element according to  claim 1 , wherein the particles having properties of increasing temperature durability are selected from the group consisting of heat resistant and conductive ceramic particles, and carbonaceous materials.  
     
     
         6 . Electrical connector or electrical switching element according to  claim 1 , wherein the co-deposited metallic matrix of the coating layer on the continuously coated metal strip mainly comprises one or more metals selected from the group consisting of nickel, copper, tin, zinc, chromium and alloys or combinations thereof.  
     
     
         7 . Electrical connector or electrical switching element according to  claim 1 , wherein the metallic core mainly comprises one or more metals selected from the group consisting of low carbon steel, high-strength steel, stainless steel, copper, bronze, brass and multilayer composites alloys or mixtures thereof.  
     
     
         8 . Electrical connector or electrical switching element according to  claim 1 , wherein the distributed particles have a size in the range of 0.001-15 μm.  
     
     
         9 . Electrical connector or electrical switching element according to  claim 1 , wherein the volume fraction of the distributed particles in the co-deposited coating layer is in the range of 0.7% to 30% of the volume of the coating layer.  
     
     
         10 . Electrical connector or electrical switching element according to  claim 1 , wherein the thickness of the metal strip is in the range of 0.1 to 1.5 mm.  
     
     
         11 . Electrical connector or electrical switching element according to  claim 1 , wherein the coating layer has a thickness in the range from 0.2-10 μm.  
     
     
         12 . Electrical connector or electrical switching element according to  claim 1 , wherein the particles of at least one group are homogeneously distributed in the coating layer.  
     
     
         13 . Method for the manufacture of an electrical connector or electrical switching element according to  claim 1 , comprising: 
 feeding a metallic core through a galvanic bath and    depositing a coating layer on at least one side of the metallic core in a continuous or semi-continuous manner, wherein a metal matrix and particles selected from the group of particles having electrically conductive properties, particles having lubricating properties, particles having wear resistance properties or particles having properties of increasing temperature stability and combinations thereof, are co-deposited on the metal core to form the coating layer, and    manufacturing the electrical connector or electrical switching element from the coated metal core.    
     
     
         14 . Continuously coated metal strip according to  claim 32 , for the manufacture of components for electrical connectors or electrical switching elements comprising said metallic core and said galvanically deposited metal containing coating layer, the metal containing coating layer being deposited by electrolytic composite plating and the coating layer comprises said metal matrix and distributed therein particles selected from the group consisting of particles having wear resistance properties.  
     
     
         15 . Continuously coated metal strip according to  claim 14 , wherein the particles having wear resistance properties are selected from the group consisting of ceramic particles, and optionally carbonaceous nanotubes.  
     
     
         16 . Continuously coated metal strip according to  claim 32 , for the manufacture of components for electrical connectors or electrical switching elements comprising 
 said metallic core and a galvanically deposited metal containing coating layer,    the metal containing coating layer being deposited by electrolytic composite plating and the coating layer comprises said metal matrix and distributed therein particles selected from the group of electrically conductive particles, selected from the group consisting of electrically conductive ceramic materials comprising borides,; nitrides sulfides, and electrically conductive oxides.    
     
     
         17 . Continuously coated metal strip according to  claim 32 , for the manufacture of components for electrical connectors or electrical switching elements comprising said metallic core and said galvanically deposited metal containing coating layer, the metal containing coating layer being deposited by electrolytic composite plating and the coating layer comprises said metal matrix and distributed therein particles selected from the group of particles having lubricating properties, selected from the group consisting of polymers, ceramic particles, and lubricating means containing capsules.  
     
     
         18 . Continuously coated metal strip according to  claim 32 , for the manufacture of components for electrical connectors or electrical switching elements comprising said metallic core and said galvanically deposited metal containing coating layer, the metal containing coating layer being deposited by electrolytic composite plating and the coating layer comprises said metal matrix and distributed therein particles selected from the group of particles having properties of increasing temperature durability, selected from the group consisting of heat resistant and conductive ceramic particles.  
     
     
         19 . A method of use of a continuously coated metal strip according to  claim 32 , comprising manufacturing an electrical connector or electrical switching element comprising at least a portion of the strip.  
     
     
         20 . Method for the manufacture of a continuously coated metal strip according to  claim 32 , wherein a metallic core is fed through a galvanic bath and a coating layer is deposited on at least one side of the metallic core in a continuous or semi-continuous manner, wherein a metal matrix and particles selected from the group of particles having electrically conductive properties, particles having lubricating properties, particles having wear resistance properties of particles having properties of increasing temperature stability and combinations thereof, are co-deposited on the metal core to form the coating layer.  
     
     
         21 . Electrical connector or electrical switching element according to  claim 1 , wherein the electrically conductive particles are selected from the group consisting of carbonaceous materials selected from the group consisting of soot, graphite and carbonaceous nanotubes, and electrically conductive ceramic materials comprising borides selected from the group consisting of titanium boride and iron boride; nitrides selected from the group consisting of titanium nitride and chromium nitride; sulfides selected from the group consisting of titanium sulfide, tantalium disulfide and molybdenum disulfide, and titanium oxide.  
     
     
         22 . Electrical connector or electrical switching element according to  claim 1 , wherein the particles having lubricating properties are selected from the group consisting of polymers, selected from the group consisting of PTFE, polyimide and polyamide, carbon containing particles selected from the group consisting of essentially pure carbon and graphite, ceramic particles selected from the group consisting of molybdenum disulphide and borium nitride, and lubricating means containing capsules selected from the group consisting of capsules containing polyphenylether or organic lubricating means, and optionally the particles having lubricating properties also having corrosion inhibiting additives.  
     
     
         23 . Electrical connector or electrical switching element according to  claim 1 , wherein the particles having wear resistance properties are selected from the group consisting of ceramic particles selected from the group consisting of aluminium oxide, zirconium oxide, silicon carbide, boron nitride and titanium nitride, and optionally carbonaceous nanotubes.  
     
     
         24 . Electrical connector or electrical switching element according to  claim 1 , wherein the particles having properties of increasing temperature durability are selected from the group consisting of heat resistant and conductive ceramic particles selected from the group consisting of aluminium oxide, zirconium oxide, silicon carbide, diamond-like boron nitride and titanium nitride, and carbonaceous materials selected from the group consisting of soot, graphite and carbonaceous nanotubes.  
     
     
         25 . Electrical connector or electrical switching element according to  claim 1 , wherein the distributed particles have a size in the range of 0.1-15 μm.  
     
     
         26 . Electrical connector or electrical switching element according to  claim 1 , wherein the coating layer has a thickness in the range of 1-5 μm.  
     
     
         27 . Electrical connector or electrical switching element according to  claim 1 , wherein the particles of all groups of particles, are homogeneously distributed in the coating layer.  
     
     
         28 . Continuously coated metal strip according to  claim 14 , wherein the particles having wear resistance properties are selected from the group consisting of ceramic particles selected from the group consisting of aluminium oxide, zirconium oxide, silicon carbide, boron nitride and titanium nitride, and optionally carbonaceous nanotubes.  
     
     
         29 . The continuously coated metal strip of  claim 16 , wherein the coating layer comprises said metal matrix and distributed therein particles selected from the group of electrically conductive particles, selected from the group consisting of electrically conductive ceramic materials comprising borides, selected from the group consisting of titanium boride and iron boride; nitrides selected from the group consisting of titanium nitride and chromium nitride; sulfides selected from the group consisting of titanium sulfide, tantalium disulfide and molybdenum disulfide, and titanium oxide.  
     
     
         30 . The continuously coated metal strip of  claim 17 , wherein the coating layer comprises a metal matrix and distributed therein particles selected from the group consisting of particles having lubricating properties, selected from the group consisting of polymers selected from the group consisting of PTFE, polyimide and polyamide, ceramic particles selected from the group consisting of molybdenum disulphide and borium nitride, and lubricating means containing capsules selected from the group consisting of capsules containing polyphenylether or organic lubricating means.  
     
     
         31 . The continuously coated metal strip of  claim 18 , wherein the heat resistant and conductive ceramic particles are selected from the group consisting of aluminium oxide, zirconium oxide, silicon carbide, diamond-like boron nitride and titanium nitride.  
     
     
         32 . Continuously coated metal strip for the manufacture of components for electrical connectors or electrical switching elements comprising a metallic core and a galvanically deposited metal containing coating layer, the metal containing coating layer being deposited by electrolytic composite plating and the coating layer comprises a metal matrix and distributed therein particles selected from the group consisting of particles having wear resistance properties, electrically conductive particles, particles having lubricating properties, particles having properties of increasing temperature durability and combinations thereof.